Broken IHKA Flap

[chetbacon]

Hi there, so yesterday i was fixing my flapper motor mounts and the little arm that actuates the flaps fell inside the airbox. When trying to look for access I forced the main flap on the left side and it broke the mechanism that connects it to the motor that opens it(i assume). Is there any way i can fix this or do I have to replace the whole air box?

https://www.youtube.com/watch?v=wtu6AdLMvLs
As you can see in this video the left main flap doesn't actuate.
Any help will be welcomed.

[shogun]

stepper motor fixes, some links
https://www.shiftbmw.com/model/e32/center-vents/
http://www.bimmerboard.com/forums/posts/200205/
https://dd.jpn.org/BMW_HP/20050329/index.shtml
https://www.bimmerforums.com/forum/showthread.php?2450902-DIY-IHKA-mixer-flap-motor-mount-completely-broken
http://www.e32-schrauber.de/bmw/s-ihka.htm
as I had a similar problem with no air from vents, I investigated further on my car and we found no broken stepper motor mount, but the stepper motor did not hold in place with the clips, so we fixed it with zip tie, works like a charm now.
Have made a youtube on my spare IHKA unit to show how the flaps work https://www.youtube.com/watch?v=pCzWommF60A&list=UUJ-2mlpcE7qOUN0dHkbYIwQ&index=2
http://www.bimmerboard.com/members/hairwithit/actuator%20released%20from%20holder.jpg

[chetbacon]

Thanks Shogun. I'll have to do some more research to see how to fix that top black flap. Thanks for the links. But from what i gathered with minimal reading of the service bulletin you shared IHKA unit has to come out, most likely, to get access to the stepper motor i need to fix.

[shogun]

I did the repair without removing the IHKA, I could fix it with a zip-tie. Motors 3 and 6 are for that https://www.shiftbmw.com/model/e32/ihka-components-and-system/

[sugaki]

Hard to see what's going on with the left side as the flap operating mechanism is in the shadow. Hard to tell, but it looks like the stepper motor on the left side has its plastic housing intact? The stepper motor is connected to a metal rod which then lifts or lowers the mechanism to open/close the flap. Is the metal rod still linked to the stepper motor? Is the stepper motor housing intact?

[shogun]

yes, that is important, on my IHKA the stepper motor clips which hold the motor in correct position, were too soft = causing the motor to flip out of position, that caused the metal rod linked to the stepper motor and flap to dis-connect. With zip ties I fixed fixed the motor in position and that works now since > 10 years. Stepper motor housing was not broken on my one, but also this was fixed by other members, see links